Post on 04-Apr-2018
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7/31/2019 Improvement on FIFO
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IMPROVEMENT ON FIFO
PROCESS
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Current FIFO process is un control due to we dont have the identification of
earlier production output that can be controlled in the system and in theactual process-( Batch No is not defined and Delivery Note is not stated
what is the earlier out put that have to be delivered first)
IF Batch No is stated in the Delivery Note, Warehouse will have difficulty to
locate the stock with the mentioned batch No
BREAKING
FIFO RULE
DEAD STOCK
CUSTOMER COMPLAINT
HIGH INVENTORY LEVEL
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FLOW OF DELIVERY FIFO PROCESS MAP
CUSTOMER CSR PRODUCTION LOGISTIC
NO
YES
Purchase
Order
Sales
Order
Production
Process
stock
ready?
Finish
Good c/w
batch
number
Start
Delivery Plan based
on PO details
Delivery Note
creation with batch
No
Delivery to customerEnd
pick pack load follow the
batch no in the Delivery
Note
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CTQ:CONTROLABLE FIFO PROCESSGOALS SCOPE
DELIVERY NOTE WITH
BATCH NO. FOLLOW
FIFO
LAMIPAK SDA
TEAM MEMBER
Project Leader : YUNI
Member : IT TEAM
LOGISTIC TEAM
PPIC TEAM
MANUFACTURING TEAM
QC/QA TEAM
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SIPOC PROCESS MAP
DELIVERYPLAN
PICK PACK LOADING AT
SUPPLIER INPUT PROCESS
DELIVERYNOTE FIRST
IN FIRST OUT
CSR
CUSTOMERSWAREHOUSE
WAREHOUSE
CUSTOMER OUTPUT
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First In First Out
Identify the earlier production output Locating the earlier production output
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Identify the earlier production out put
Set up the batch number
- by shift
- Identification need : date/machine no/shift no
- Create the secondary batch no if rework is needed, asrework is part of our production process, but this batch Nowill be able to be traced in the system
Implementation batch No- System will produce Batch No automatically when
production issued POV on the pass on/hold/reject and alsowhen POVR is issued
- Warehouse will posting the FG with batch No.- Identification on the box by stated in the Label
- If rework is needed, than the previous label is replaced bythe new one after rework is done
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XX X XX XXX X X 09A01AMS11
This Date is Production Schedule Date
YEAR : 09
MONTH : A
A Jan
B Feb
C Mar
D Apr
E May
F June
Batch Numbering Sequence Without Rework
G July
H August
J Sept
K Oct
L Nov
M Dec
DATE : 01
MACHINE CODE : AMS
MACHINE NO. 1
SHIFT : 1
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XX X XX XXX X X X 09A15AMS11A
This Date is Rework Date
YEAR : 09
MONTH : A
A Jan
B Feb
C Mar
D Apr
E May
F June
Batch Numbering Sequence With Rework
G July
H August
J Sept
K Oct
L Nov
M Dec
DATE : 01 -30
MACHINE CODE : AMS
MACHINE NO. 1
SHIFT : 1 Identified Rework process : A, B,C etc
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Identify the Storage Location and BIN in the warehouse
- Warehouse optimization lay out , number of SLOC andBIN
- Re-arrange W/H : identify dead stock,slow moving andfast moving product
- New W/H for dead stock and slow moving
Locating the Earlier production output
- Identify each product in each SLOC/BIN ?- Numbering the racking by SLOC and BIN
Manage warehouse management in the system
- Adding SLOC and BIN once W/H do posting F/G
- Blocking the each SLOC and BIN capacity in the system
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Control FIFO Process
1. Delivery Note only can be printed after stock is ready in
the warehouse
2. Eliminating DN1, agreed by all function, Urgency of the
Delivery is controlled by having a better OrderManagement,Inventory Report and PPC Control on the
Production output
3. Batch No must be stated in the Delivery Note4. No option for batch No selection
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Support need
Speed up the process on the pick pack load ,
- Forklift - maintenance
- Hand pallet availability- W/H capacity is only enough for the Fast Moving Product
Rework Process
- Due to second label have to be done after Rework, so QCshould have the Box Label stock
- Rework process will be reviewed on the separate project
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INVENTORY STATUS
PLANT :RM/FG/GIT :
PRODUCT CODE
Product Name
date details Unrestricted restricted Total
Stock 23-Jun 5000forecast order
Safety Stock
Process order 1-Jul 5000
lannin order 1-Au 20000
Sales Order 1-Jul SO No. -10000STP0 -20000
Delivery
QC
and each will be link to each batch No
New Inventory Report will update how many we have in the production Line, or how many demand we have from
customer, better planning process
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PPIC PRODUCTION QC LOGISTIC
PASS ON
Production
Process
Finish
Good c/w
batch
number
planning process
schedule
produksi
reject
machine
QC Inspection
processPOV
labelling
batch no auto
generated from
system QC
result
REJECT
Qty sched
prod will
be reduce
auto once
FG is
posting in
W/H
Improvement on Controlling the Production Schedule Result to Eliminate the DN 1
process
rework process
POVR
labelling
process
batch no auto
generated from
system
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PROJECT MILESTONE
PIC 6/22 6/29 7/6 7/13 7/20 7/27 8/3 8/10 8/17 8/24 8/31 9/7 9/14 9/21 9/28
Define the problem statement and CTQ Nenden
Define the batch numbering order ALL
New Process flow of DN creation Nenden
New Process flow of DN creation Nenden
Identify batch No in the Box Label ALL
Process batch No in the system
Beny/Gunawa
n
Process New Delivery Note Creation in
the system
Beny/Gunawa
n
Identify SLOC and BIN based on W/H
layout Yuni/Udin
Identify SLOC and BIN based on W/H
layout in the System
Beny/Gunawa
n
Transfer of Dead stock and Slow Moving
to new place Include define new W/Hplace Yuni/Udin
Re-arrange W/H with identify Dead
stock,Slow Moving, fast Moving Yuni/Udin
Racking numbering with SLOC and BIN Yuni/Udin
Blocking SLOC /BIN Capacity
Beny/Gunawa
n
Eliminating DN1 process All
Warehouse Total Cost (New W/H,
Rearrange, Hand pallets etc to improve
process pick pack load Yuni/Udin
IT Total Cost ( Infrastructure or others?)
eny unawa
n
Training and socialitation of FIFO
Process
Yuni/
Gunawan
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Outstanding item
Costing IT
IT Time line to support this new process, Batch no and DN creation
and SLOC/BIN
Costing warehouse
Warehouse Lay out and optimization capacity
W/H details on Dead Stock,SMI, and Fast Moving product
c e u e o rearrangemen
Socialitation and training of this new project